Baseball-style cap attachable brim

ABSTRACT

A brim extender attaches to any standard baseball-style cap and may provide one or more functions, such as (1) extending sun protection along the sides and posterior portion of the hat, (2) changing the style and appearance of the hat, (3) providing a new promotional item (e.g., a new thing that can be labeled, colored, or styled to market a brand), and/or (4) providing an added barrier between the head and the crown of the cap to shield or partially shield the cap from perspiration and other substances coming from the scalp or hair.

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57.

BACKGROUND Field

Improvements to baseball-style caps (or simply “baseball caps” or “caps”).

Description of the Related Art

Baseball-style caps have become very common throughout the world and are used for many purposes by men, women, and children. Such caps typically include a relatively stiff front brim or “bill” portion attached to a soft domed “crown” portion. They may be made of various solid or mesh fabrics, leather, or other such materials. The bill portion may be pre-shaped into an arched contour and is often reinforced with plastic or cardboard. The user can generally manually bend the bill portion to adjust the arch. The crown portion may be adjustable to fit heads of various circumferences. The adjustment device, usually in the posterior part of the cap is sometimes a strip of fabric or plastic, and may include a buckle device, Velcro, or other interlocking mechanism. Caps may also include an elastic headband portion to enable an adjustable fit. Although referred to here as “baseball-style caps,” we use this term to describe a wide variety of similar caps that may be referred to in the market place as golf caps, trucker hats, fitted caps, snap-back caps, and other such terms that all describe hats made of various materials that consist of a crown and frontal brim.

Once used primarily by baseball players, such caps are now used in many other sports, workplaces, and recreational environments. They are often also manufactured and sold as promotional items, meaning that a business or team may print a logo and/or use a color scheme on the hat that helps promote a particular brand. Logos may be embroidered, printed, or otherwise attached to the cap. Despite the wide number of purposes for baseball-style caps and the large number of manufacturers, such caps have a relatively common shape.

SUMMARY

Baseball-style caps afford some head and facial sun protection, but may not adequately shade the ears, side of the face, or back of the neck. Thus, disclosed herein are improvements to baseball-style caps in the form of an attachment that may serve one or more functions, including: (1) extending sun protection along the sides and posterior portion of the hat, (2) changing the style and appearance of the hat, (3) providing a new promotional item (e.g., a new thing that can be labeled, colored, or styled to market a brand), and/or (4) providing an added barrier between the head and the crown of the cap to shield or partially shield the cap from perspiration and other substances coming from the scalp or hair.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a person wearing a baseball cap with a brim extender attached thereto.

FIG. 2A illustrates a cap and a brim extender.

FIG. 2B is a bottom view of the cap and brim extender with a portion of the bill extending through the slit in the brim extender.

FIG. 2C is a top view of the cap with the brim extender attached via insertion of the bill through the slit of the cap.

FIG. 3A is a top view of a hat prior to attachment of the brim extender.

FIG. 3B is a bottom view of the cap and brim extender with a portion of the bill extending through the slit in the brim extender.

FIG. 3C is a top view of the cap with the brim extender attached via insertion of the bill through the slit of the cap.

FIG. 4A is a top view and FIG. 4B is a perspective view of another example brim extender.

FIGS. 5A-5I are a series of representations of the brim extender being attached to a cap.

FIG. 6 illustrates the cap with the brim extender attached, ready for use by a wearer.

FIG. 7 illustrates a two layer brim extender, including layers and.

FIG. 8 illustrates an example manufacturing environment that may be used to manufacture brim extenders.

DETAILED DESCRIPTION

FIG. 1 illustrates a person or user 160 wearing a baseball cap 100 with a brim extender 110 attached thereto. In this example, a bill 101 extends ahead of a wearer 160 to provide some shade on the wearer's face. The brim extender 110 advantageously enhances the overall sun protection of the combined cap/brim extender apparatus by providing additional shade to the sides and back of the users face and neck.

FIG. 2A illustrates a cap 200 and a brim extender 210. The cap includes a bill 201 and crown 202 portions. The crown 202 includes an adjustment device 220, which may include an interlocking mechanism, a buckle, hook and loop material, and/or other material that allows a sized of the crown 202 to be adjusted (e.g., to fit larger or smaller heads). The bill 201 may be a relatively stiff material while the crown 202 may be a more flexible material configured to fit on a person's head. For example, the bill 201 and crown 202 may be made of foam, plastic, leather, and/or other materials. In the example of FIG. 2A, the brim extender 210 is configured to attach to the cap 200 to provided one or more of the advantages noted above. For example, the brim extender 210 may provide additional protection from the sun, beyond the shading provided by the bill 201 and crown 202 of the cap 200.

In the example of FIG. 2A, the brim extender 210 is shaped to enable attachment to the cap 200 without strings, tape, glue, or mechanical fasteners. In this embodiment, the brim extender 210 includes an “under the crown” portion 212 (e.g., including the multiple tabs 213 in the example of FIG. 2A) configured to fold between the crown 202 of the cap 200 and the head of a wearer. Depending on the embodiment, this under the crown portion 212 may be of various shapes and sizes. For example, the under the crown portion 212 of the brim extender 210 includes several tabs 213 that are divided with slits in material of the brim extender 210, while the under the crown portion of the brim extender 310 (FIG. 3A) includes four tabs 313 spaced apart by larger openings (e.g., material that is removed during the manufacturing or assembly process), and an under the crown portion of the brim extender 410 (FIG. 4A) includes a single tab under the crown portion 412. Other variations in the under the crown portion of the brim extender are contemplated, such as to include any other quantity, shape, spacing, etc. of tab portions.

Returning to FIG. 2A, the brim extender 210 also includes a slit-like opening 214 configured to enable passage of the bill 202 of the baseball cap 200 such that a portion 216A of the brim extender 210 comes to lie above the brim. A shading portion 216 also extends outward around the sides and back of the crown 202 when worn by a wearer, while the under the crown portion 212 folds between the crown 202 and the wearer's head. This combination of “over the bill” and “under the crown” portions of a single continuous attachment enables the brim extender 210 to remain in position when worn, while still being easily removable when desired. In some embodiments, the brim extender 210 may include one or more fixation device, such as a clip, pin, hook and loop material, and/or glue, to provide further attachment of the brim extender 210 and the cap 200. In the example of FIG. 2A, no additional fixation device is used to keep the brim extender 210 in proper position.

The brim extender 210 may vary in shape, such as smooth contour or jagged contour. In some embodiments, the brim extender 210 is a relatively flat sheet of material, or may be made of a material that simulates appearance of human hair, for example. Portions of the bill extender 210 may be labeled via embroidering, printing, or other-attachment. As discussed further below with reference to FIG. 8, brim extenders may be manufactured from a single flat piece of plastic, foam, fabric, rubber, neoprene, leather or other such substance, or produced from a variety of substances that are sewn or otherwise bonded together (see, e.g., FIG. 7). Brim extenders may be sold as standalone products (e.g., for attachment to a cap of the purchaser's choice) and/or may be packaged with a cap (e.g., with a similar color, style, etc.). The design could be incorporated into a new and distinct style of baseball cap.

FIG. 2B is a bottom view of the cap 200 and brim extender 210 with a portion of the bill 201 extending through the slit 214 in the brim extender 210. As shown, the tabs 213 are configured to be pressed into the crown 202 of the cap 200 when placed on the head of a wearer, such that compression of the tabs 213 between the wearer's head and the crown 202 of the cap maintain position of the brim extender 210 with reference to the cap 200. FIG. 2C is a top view of the cap 200 with the brim extender 210 attached via insertion of the bill 201 through the slit 214 of the cap 200. As shown, with the brim extender 210 attached in this manner, the area of shading provided to a wearer is significantly increased.

FIG. 3A is a top view of a cap 300 prior to attachment of the brim extender 310. As noted above, the brim extender 310 includes four tabs 313 configured to fit between a head of the wearer and the crown 302 of the cap 300. FIG. 3B is a bottom view of the cap 300 and brim extender 310 with a portion of the bill 301 extending through the opening 330 in the brim extender 310. As shown, the tabs 313 are configured to be pressed into the crown 302 of the cap 300 when placed on the head of a wearer. FIG. 3C is a top view of the cap 300 with the brim extender 310 attached via insertion of the bill 301 through opening in the brim extender 310. In this example, the brim extender 310 includes a larger front shading portion 311 that extends forward beyond the length of the bill 301. In other embodiments the length of the front portion 311 may be even larger. Similarly, the length of side and rear portions of the brim extender 310 may be larger or smaller in other embodiments.

FIG. 4A is a top view and FIG. 4B is a perspective view of another example brim extender 410. In this example, the under the crown portion includes an attachment tab 413 configured to fit through an attachment slit 414 to attach the brim extender 410 to a cap. In particular, an expanded portion 413A of the tab 413 is wider than the slit 414 so that once the tab 413A is through the slit (e.g., by manually compressing the expanded portion 413A as pushing through the slit 414), the expanded portion 413A maintains the attachment of the tab 413 around an adjustment device 220 (e.g., as shown in FIG. 2A) of a cap. In the example of FIG. 4A and 4B, the brim extender 410 also includes adhesive tabs 415 configured to further secure the brim extender 410 to the bill of the cap 400. In some embodiments, there may be none, one, or more than two tabs 415. In another embodiment, the attachment tab 413 may not pass through a slit but instead pass through a retaining strap or keeper that is sewn in the approximate position of slit 414. In one embodiment that attachment tab 413 does not have an expanded end, but instead has a fold or seam that loops under a retaining strap or keeper.

FIGS. 5A-5I are a series of representations of the brim extender 410 being attached to a cap 400. Beginning with FIG. 5A, the cap 400 is shown separate from the brim extender 410. As noted above, the brim extender 410 may be acquired (e.g., as a gift or purchase) separately from the cap 400 or may be packaged with the cap 400. In FIG. 5B, a user removes a backing material 416 from one of the tabs 415. A similar process may be performed on the other tab 415 to expose an adhesive material on the tabs 415. In this example embodiment, the adhesive on the tabs 415 adhere to a bottom side of the bill 401 to provide a more secure connection between the brim extender 410 and the cap 400. Continuing to FIG. 5C, the bill 401 of the cap 400 is inserted into the opening 430. FIG. 5D illustrates the tabs 415, with the adhesive surface exposed, being pushed under the bill 201. FIGS. 5E-5H illustrate the bottom side of the cap while attaching the attachment tab 413 around an adjustment device 420 of the cap 400. As show in FIG. 5H, with the attachment tab 413 wrapped around the adjustment device 420 of the cap 400, the expanded portion 413A extends through the slit 414 and maintains the tab 413 around the adjustment device 420 of the cap. FIG. 51 illustrates a user depressing the adhesive tabs 415 onto the bottom surface of the bill 401. FIG. 6 illustrates the cap 400 with the brim extender 410 attached, ready for use by a wearer. In one embodiment, user instructions may be printed on the brim, such as along the underside of the posterior portion of the brim, or the instructions may be attached as a bonded or sewn-on label.

FIG. 7 illustrates a two layer brim extender 710, including layers 712 and 714. In this embodiment, the layers 712 and 714 may comprise the same or different materials and may provide the same or different functionalities. For example, one of the layers may be a more rigid backing or interfacing material while the other layer may be a softer or elastic material. In one example, layer 712 is a semi-stiff backing bonded or sewn to a printable, flexible and/or elastic fabric 714. In one embodiment, the brim extender may include two layers, in which one of the layers is a somewhat stiff backing or interfacing fabric (such as buckram, Pellon®, plastic) and another layer is made of an elastic fabric, with the elastic fabric's inner perimeter forming an smaller oval shape than the backing material. As a result, the elastic fabric may help keep the brim extender in place by stretching around the crown of the cap. In one embodiment, the brim extender may include an elastic band that is sewn or bonded along the inner perimeter of the brim extender. In one embodiment, the brim extender contains three layers, with a backing fabric layered between two elastic fabrics of different color or style, so that the brim extender can be worn with either side facing upward. In one embodiment, a portion of the brim extender may be attached to the bill of the cap using a plastic or metal clip, such as a decorative paper clip or golf ball marker clip. Thus, in some embodiments, an inner perimeter of the brim extender 710 that fits around the cap crown is stretchable, and also, the upper and/or lower surface of the brim is printable or any portion of the brim may be embroidered and have a label sewn-on. The layers may be bonded together in any manner, such as via an adhesive. Multiple layers may be used in any of the other brim extender embodiments discussed herein.

FIG. 8 illustrates an example manufacturing environment that may be used to manufacture brim extenders. In this example, a roll of material (e.g., single or multi-layer foam or material) 810 is receiving by a stamping machine 820 configured to pull the material through the machine 820 and to stamp (or otherwise cut-out) multiple brim extenders 830. The process may be entirely or partially automated, such that the brim extenders 830 may be easily manufactured in bulk. In this example, broken lines of the brim extenders 830 show the cuts in the material 810. In some implementations, the machine 820 may also include a marking component configured to print, spray, iron-on, or otherwise apply coloring to the brim extenders 830, such as to provide an advertising or marketing message on each of the brim extenders 830. In some embodiments, the material 810 is pre-marked with such marketing information, so that when the space of the brim extenders 830 is cut from the material, the advertising is appropriately positioned on the brim extenders 830. 

What is claimed is:
 1. A brim extender comprising a substrate having: a front portion and a rear portion defining a central aperture sized to receive a crown portion of a baseball cap; an attachment tab extending from the rear portion into the central aperture; an attachment slit extending through the rear portion of the flexible substrate, the attachment slit sized and positioned to allow a portion of the attachment tab to pass therethrough; and one or more tabs on the front portion of the flexible substrate, the tabs configured to stabilize the brim extender upon the baseball cap.
 2. The brim extender of claim 1, wherein the attachment tab includes an expanded portion that is wider than the attachment slit.
 3. The brim extender of claim 1, further comprising a non-stick backing material on each of the one or more tabs, the backing material configured for removal so that an adhesive material on the one or more tabs is exposed.
 4. A brim extender comprising a substrate material having: a front portion and a rear portion defining a central aperture sized to receive a crown portion of a baseball cap, wherein the front portion rests on a bill of the baseball cap when the crown portion extends through the central aperture; a plurality of tabs extending into the central aperture, the tabs configured for compression between a head of an individual and an inner surface of the crown portion of the baseball cap.
 5. The brim extender of claim 4, wherein the plurality of tabs are spaced apart by openings.
 6. The brim extender of claim 4, further comprising: a slit through the front portion of the baseball cap sized to receive the bill of the baseball cap.
 7. The brim extender of claim 1, wherein the brim extender is configured for attachment to the baseball cap without sewing onto the baseball cap and without a separate clip, string, or other attachment mechanism.
 8. The brim extender of claim 1, further comprising an elastic band sewn or bonded to the substate about the central aperture.
 9. A method of manufacturing brim extenders comprising: providing a machine configured to receive a substrate material and automatically cut a plurality of brim extenders from the substate material, each of the brim extenders having: a front portion and a rear portion defining a central aperture sized to receive a crown portion of a baseball cap; an attachment tab extending from the rear portion into the central aperture; an attachment slit extending through the rear portion of the flexible substrate, the attachment slit sized and positioned to allow a portion of the attachment tab to pass therethrough; and one or more tabs on the front portion of the flexible substrate, the tabs configured to stabilize the brim extender upon the baseball cap.
 10. The method of claim 9, wherein the brim extenders are cut from a single sheet of the substate material without requiring sewing or bonding after cutting.
 11. The method of claim 9, wherein the substrate material comprises foam or neoprene.
 12. The method of claim 9, wherein the one or more tabs are configured to be bonded to an undersurface of brims of baseball caps.
 13. The method of claim 7, wherein the brim extenders are configured for attachment to baseball caps without sewing onto the baseball caps and without a separate clip, string, or other attachment mechanism.
 14. A brim extender comprising a substrate having: a first layer comprising a substantially stiff backing material, the first layer having a first central aperture size to receive a crown portion of a baseball cap; a second layer comprising an elastic fabric having a second central aperture smaller than the first central aperture; wherein the first and second layer are bonded or sewn together to form the brim extender that is held in place on the baseball cap at least by the elastic fabric stretching around the crown portion of the baseball cap.
 15. The brim extender of claim 14, wherein the second central aperture is substantially oval.
 16. The brim extender of claim 14, further comprising an elastic band sewn or bonded along an inner perimeter of one or more of the first and second layers.
 17. The brim extender of claim 14, further comprising: a third layer comprising an elastic fabric, wherein the first layer is bonded between the second and third layers.
 18. The brim extender of claim 17, wherein the second and third layers are different color or style, such that the brim extender is reversible.
 19. The brim extender of claim 14, wherein the first layer comprises an interfacing fabric or plastic. 